Feature

Technologies Creating Change

1954
Ueda Works

46

November
2018

COLUMN
Cover image:

Ueda Works
1954

In the 1950s, as the Japanese electronics industry continued to grow, manybroadcasting stations were established, with public radio broadcasts beginning in 1951,
and television broadcasts beginning in 1953.
The dawn of the radio and television era was the construction of a microwave
communication network by NTT Corporation (Nippon Telegraph and Telephone Public
Corporation, the predecessor of the current NTT group).
Not just communications companies, all of society benefitted from the booming
consumer economy of 1950 to 1953.
At the same time, orders took off for hand-powered generators and radio power
supplies, and production at our Ueda Works was extremely busy.
Hand power generators were a necessity for powering lifeboat radios in the event of an
accident. Much of the demand for these products, which would later be legally mandated,
was met by SANYO DENKI.
We also received orders from the Defense Agency for portable gasoline generators.
These were used as power supplies for portable communications units, such as werecarried in trailers.
In addition to such large orders, there was high demand for power supplies for
emergency marine radios and for converters for fish detectors, and high production at
Ueda Works continued into the latter half of the 1950s.

46
November 2018

SANYO DENKI TECHNICAL REPORT
C

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T

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Technologies Creating Change

T

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Executive Operating Officer Chihiro Nakayama

Feature: Technologies Creating Change

13■ Cooling Systems Division

Technologies Creating Change

Masato Murata..................................................................... 3

High Airflow Long Life Fan /High Airflow Long Life Splash Proof Fan
San Ace 140L and San Ace 140W Masahiro Koike and Others ................................................... 7
High Static Pressure Long Life Counter Rotating Fan
San Ace 60L 9CRLA Type Yoshihisa Yamazaki and Others ........................................................... 13■ Power Systems Division

Development of UPS Products Equippedwith Lithium-Ion Batteries Creating Change
and Offering New Value Masahiko Nagai ................................................................................ 17
Development of the Small-Capacity UPS
SANUPS N11C-Li Series Shota Ozawa and Others ........................................................................ 21■ Servo Systems Division

Servo System Technologies Creating
Monozukuri Changes Hideaki Kodama and Others ......................................................................... 26
Development of the SANMOTION R 3E Model
400 VAC Input Servo Amplifier (150 A, 300 A) Haruhiko Chino and Others ....................... 31

Technologies Creating Change

Chihiro Nakayama
Executive Operating Ofﬁcer

SANYO DENKI Group’s 8th Mid-term Management Plan is a 5-yearplan started in April 2016, and marks its third year in 2018.
One of the 8th Mid-term Management Plan’s key policies is “toestablish a corporate culture capable of transforming environmental
changes into business opportunities.”
The business environment is constantly changing. We at SANYODENKI Group will stay abreast of these changes and aim to build
a strong corporate culture that enables us to transform change into
opportunity.
To realize this key policy, we have implemented one of our action
guidelines “challenge your weakness and turn it into your strength,”
promoting “specialists in change” objective. The results of these policies
are starting to appear thanks to the various ideas and actions of alldivisions and employees of SANYO DENKI Group.

Now, let’s look to the theme of this issue of Technical Report:
Technologies Creating Change. It has a keyword “change” in common
with the abovementioned policy. What does it exactly mean?
The 8th Mid-term Management Plan has another key policy of “develop
products that make new dreams come true.” In more concrete terms,
this means to “create new value to our customers and new products thatrealize dreams together with the customers.”
In accordance with these policies, SANYO DENKI Group’s Design
and Development divisions have established the following productdevelopment themes: “performance and functions that are friendly
to people and to the environment,” “performance and functions
characterized by safety and ease of use,” and “performance and functions
optimized for robotization and automation.”

1

SANYO DENKI Technical Report No.46 November 2018

Products with such performance and functions bring about changes inour customers and our surroundings, which in turn produce “new value”
and “new dreams,” thus leading to the realization of our policies. The
products we develop create positive changes in our customers and oursurroundings, and this can be entitled as “technologies creating change.”

By leveraging these “technologies creating change,” SANYO DENKI
has developed unique, never-before-seen products and introduced themto the market.
Our Cooling Systems Division has produced fans offering various
environmental durability features such as Long Life Fans, Splash Proof
Fans, Oil Proof Fans, and Wide Temperature Range Fans. These fansthat can be used in harsh environments are creating new value.
The Power Systems Division has developed and released UPSs that
adopt lithium-ion batteries as an alternative to lead-acid batteries. These
products are safe and user-friendly because they can be used in a broad
range of environments from extreme cold to extreme hot, and require no
maintenance for a period of ten years.
Our Servo Systems Division has developed servo amplifiers capableof transferring significantly larger amounts of data. These products canhelp equipment turn into an IoT-enabled system, and therefore perfectly
conform to the theme of robotization and automation.

This issue of Technical Report introduces some of our “technologies
creating change.”
SANYO DENKI will further accelerate the development of thesetechnologies and endlessly create and launch products that make new
dreams come true in order to contribute to society.

SANYO DENKI Technical Report No.46 November 20182

Feature: Technologies Creating Change

Technologies Creating Change
Masato Murata

1. Introduction
SANYO DENKI’s product lineup is extremely diverse,demand from customers to extend the service life of this fan,thus achieving a maintenance-free device. In response tothis need, SANYO DENKI developed the Long Life Fan.

ranging from AC fans to DC fans, the Long Life Fan,

As a result of the Long Life Fan offering longer service

Splash Proof Fan, Counter Rotating Fan, Oil Proof Fan,

life and maintenance-free features, the demand for it grew

Wide Temperature Range Fan, Centrifugal Fan, PWM

among customers wanting to improve the reliability of their

Controller and more. Initially after development, theseproducts. For example, the product came to be adopted in

products were adopted to meet certain requirements in thehigh-reliability servers, public transportation facilities, data

market. However, each product has defining features, andprocessing equipment for financial institutions, emergency

in some cases, this leads to the product being adopted in

UPS, PV and wind power generators, industrial inverters,

new markets. For example, when our Long Life Fan was

medical equipment, and many more devices of new markets

initially developed, it was primarily used to cool telephonethat did not exist when the fan was first developed.

switchboards. In recent years, the reliability of the producthas received much attention, and this product is now used

2.2 Splash Proof Fan

in high-reliability servers where constant availability is

The Splash Proof Fan was launched in 1996. Currently, thisessential. In this way, products with defining features areproduct is available in 12 sizes, from 40 × 40 × 28 mm to ø172

creating changes in demand.

× 51 mm, and also features improved cooling performance.

Focusing on fans with features that create change, thisAt the beginning of this fan’s development, base stations

article will use the environmentally durable Endurance

were increasing with the spread of mobile phones. Initially,

Fans series—namely the Long Life Fan, Splash Proof Fan,fans were mounted within waterproof enclosures and

Oil Proof Fan, Wide Temperature Range Fan, and G Proof

circulated air to naturally cool large heat exchangers.

Fan—as examples to introduce both the circumstances that

However, as more devices became increasingly sophisticatedcreated market changes as well as the technologies found inand compact, forced air cooling became necessary. A

our products.

demand emerged for a waterproof fan that could supply anddischarge outside air, thus leading to SANYO DENKI’s

2. Background to the Developmentof Endurance Fans and Market
Changesdevelopment of the Splash Proof Fan.

2.1 Long Life Fan

new outdoor products including large LED displays, digital

With its water-resistant features, the Splash Proof Fan
harbors the potential to create a demand for use in all
outdoor devices. Specifically, this fan is used in various

As the very first of the Endurance Fans series, the Longsignage, EV quick charging station, and LED lighting. The

Life Fan was launched in 1991. Currently, this product isSplash Proof Fan is also increasingly found in indoor devices

available in 12 sizes, ranging from 40 × 40 × 28 mm to ø172 ×

that operate near water or moisture like food processing

51 mm, and features improved cooling performance.

machines, plant factories, and dishwashers.

When this fan was first developed, it had a shorter service
life than the ICT equipment it was used in (e.g. telephone3

2.3 Oil Proof Fan

switchboards) and had to undergo maintenance every three

The Oil Proof Fan was launched in 2004 and is available in

to five years. High costs of maintenance lead to strong

9 sizes ranging from 40 × 40 × 15 mm to 120 × 120 × 38 mm.

SANYO DENKI Technical Report No.46 November 2018

Technologies Creating Change

When this fan was first developed, the cooling fans used inrange of operating temperatures, therefore it is used in LED

control amplifiers of FA machine tools and industrial robots

displays, LED lighting, and other devices used outdoors

would frequently lock up and fail due to built up dust andthat are exposed to severe temperature changes. In addition

cutting oil from operating in oil mist. Such fan failures meant

to catering to natural environments, this fan also has thethat maintenance was unavoidable. The Oil Proof Fan was

potential for adoption in temperature-controlled devices

adopted to meet the need to minimize breakdown frequency.

such as freezers or high-temperature testing equipment.

Thanks to its oil-proof performance, the Oil Proof Fan
is used in industrial inverters and other factory equipment.
In addition to factory equipment, this fan is also becoming
increasingly popular for adoption in environments using
cooking oil, such as food processing machines.

2.5 G Proof Fan
The G Proof Fan was launched in 2017, and is available in
2 sizes: 120 × 120 × 38 mm and ø172 × 51 mm.
This fan was initially developed as a cooling fan able
to withstand the large G-forces created by the gantry of

2.4 Wide Temperature Range Fan

medical CT scanners which rotates at high speeds.

The Wide Temperature Range Fan was launched in 2014,

Because the G Proof Fan features G-force tolerance, it

and is available in 6 sizes, ranging from 40 × 40 × 28 mm tocan be adopted in devices with high-speed movement. For

120 × 120 × 38 mm.

example, it could be used in amusement park rides allowing

When this fan was first developed, photovoltaic and wind
power generation had just begun growing in popularity.

thrill-seekers to experience rapid acceleration, or used tocool elevator equipment.

The fan was developed to meet the demand to withstand

Table 1 shows the initial and expanded target applications

operating temperatures as low as -40˚C and as high as 85˚C,for each product series. Moreover, by developing andas it was assumed that such would be required in natural

launching products with unique features, we anticipate thatenvironments with harsh operating conditions.

even more demand will be created.

The Wide Temperature Range Fan can operate in a wide

Table 1 Initial target applications and expanded target applications
Series name

Initial targets

Expanded targets

ICT equipment

Public service devices
Network communication systems
Industrial printers
Industrial power supplies
UPS
High-reliability servers
PV / wind power generators
Industrial inverters
Base stations
Medical devices

Splash Proof Fan

Base stations

Quick charging station
Industrial inverters
Displays
Digital signage
Food processing machines
Dishwashers
Plant factories
LED lighting

Oil Proof Fan

Servo amplifiers

Industrial inverters
Motor cooling
Food processing machines

Wide Temperature Range Fan

PV / wind power generators

Quick charging station
DisplaysFreezer/refrigerator relatedPlant factories
LED lighting

G Proof Fan

Medical CT scanners

Amusement devices
Elevators

Long Life Fan

SANYO DENKI Technical Report No.46 November 20184

3. Features and Technologies
of Endurance Fanscovered the coil and live parts with waterproof material
and utilized highly water resistant material for the magnet
and other parts exposed to air. We applied further

This section introduces the features and technologies ofwaterproofing treatment to the frame and other components
exposed to the air to improve rust resistance.

the Endurance Fans that created changes in demands.

Figure 2 shows how the live parts of the Splash Proof Fan

3.1 Features and Technologiesof the Long Life Fanand the Oil Proof Fan are protected.

[Feature] Maintenance-free
In order to minimize the maintenance work required forfans, the Long Life Fan has an expected life of over 2.5 times
that of SANYO DENKI’s standard fan (100,000 hours, L10,
60˚C, rated voltage, in free air).
[Technologies]
To achieve long service life, we used material withimproved durability for our magnets and other components,and selected parts and materials that do not change overtime. Moreover, as bearing life is most affected by greasedegradation in line with temperature increase, we adopted
a frame with excellent thermal conductivity (aluminum
die-cast) and improved motor efficiency, thus suppressing
temperature increase. We also reduced bearing load andFig. 2 Protection of live parts

revised the grease type. These efforts improved bearing life.
We reduced the usage ratio of the motor drive circuit andincreased reliability.

3.3 Features and Technologiesof the Oil Proof Fan

the Long Life Fan.

[Feature] Oil-proof performance〔hours〕

Figure 1 shows the expected life of the standard fan andand oil build-up making it ideal for environments exposed toThis fan was designed to prevent failures caused by dust
1000000

Condition: Rated voltage, continuous operation, free air, 90% survival rateLong Life Fan

cutting oil mist.

Expected life 200000h (60˚C)
Expected life 180000h (60˚C)
Expected life 100000h (60˚C)[Technologies]
To ensure oil-proof performance, we completely covered

Expected life
10000
100000

Expected life 80000h (60˚C)

the coil and live parts with oil-proof material, and utilized
highly oil resistant material on the frame, impeller, magnet,

Standard Fan

and other parts exposed to air. By increasing the clearance

Expected life 60000h（60˚C）

between the tip of the impeller blades and inner surface of

Expected life 40000h（60˚C）
Expected life 30000h（60˚C）

Expected life 40000h (85˚C)

1000

0

20

40

60
80
Ambient temperature100

the frame, we reduced the possibility of the impeller locking
up even if there was oil or dust build-up.

Wide Temperature Range Fan
120

〔˚C〕

Fig. 1 Expected life of DC fans

3.4 Features and Technologiesof the Wide Temperature Range Fan[Feature] Wide operating temperature range: -40 to +85˚C[Technologies]

3.2 Features and Technologiesof the Splash Proof Fanof materials used for components and selected parts and[Feature] Waterproof performancematerials which could withstand the target operating

Protection code: Waterproof and dustproof performance

temperature range. We selected electronic componentsof IP68 and IP55* have been achieved.

with a wide operating temperature range and designed the[Technologies]

fan paying close attention to thermal characteristics. We

To ensure waterproof performance, we completely

5

We verified the thermal characteristics and durability

SANYO DENKI Technical Report No.46 November 2018

adopted a circuit configuration after sufficiently verifying

Technologies Creating Change

its operating temperature range. All of this lead to theimpeller and rotor cover. Additionally, an aluminum die-successful development of a fan capable of performing in acast frame was adopted to achieve high rigidity. Throughwide operating temperature range.

simulation analysis, we revised the structural design,
including part joints, increased strength and, ultimately,

3.5 Features and Technologiesof the G Proof Fan

achieved a G-force tolerance of 75 G.

[Feature] Ability to withstand G-forces: 75 G (at normaleach fan series in order to realize their unique features.

temperature, normal humidity, continuous operation)

By adopting the appropriate new technology for each

[Technologies]

individual feature, we have successfully developed products

Above we have introduced the technologies adopted in

In order to create rotating parts able to withstand aG-force of 75 G, we adopted a structure that integrated thewith new defining features. Table 2 shows the features andtechnologies of each series.

Table 2 Features and technologies
Series nameFeatures

Technologies

Long Life Fan

Maintenance-free• Uses parts and materials that change minimally over time
• Improved bearing life
• Improved reliability of the motor drive circuit

Splash Proof Fan

Splash Proof• Protects live parts using highly waterproof material• Uses materials with excellent water-resistance• Rustproofing on necessary areas

Oil Proof Fan

Oil-proof• Protects live parts using highly oil-proof material• Uses materials with excellent oil-resistance for the frame, impeller, and magnet• Secures sufficient clearance between the blade tips and inner surface of the
frame

Wide
Temperature
Range Fan

Wide operating
temperature
range• Uses parts and materials able to withstand high/low temperatures• Adopts a circuit configuration enabling trouble-free operation in both high andlow temperatures

G Proof Fan

Ability
to withstandG-forces• The structure of the G Force Fan features an integrated impeller and rotor cover.
• Adopts high-rigidity material for the frame• Adopts a structure of improved rigidity

4. Conclusion
This article introduced the Endurance Fans series as fansthat have defining features and have been adopted in devicesof new markets differing from the initial target market toshow how these fans have created changes in demands.
SANYO DENKI will continue assessing market needs at

Reference(1) Kesatsugu Watanabe and 6 others: Development of Long LifeFans
SANYO DENKI Technical Report No.1 pp. 5-8 (1996)(2) Honami Osawa and 3 others: Development of Splash Proof Fans
SANYO DENKI Technical Report No.3 pp. 6–8 (1997)(3) Hidetoshi Kato and 3 others: Oil Proof Fans San Ace 40WF, Sanan early stage and, through existing and new technologies,

Ace 60WF, and San Ace 120WF

develop products with features that satisfy such needs and,SANYO DENKI Technical Report No.19 pp. 17–19 (2005)

ultimately, create new demands.

(4) Osamu Nishikawa and 3 others: Wide Temperature Range Fan
San Ace T Series 9GT Type*Shows the protection rating for the San Ace W series.
The protection rating (IP code), is defined by IEC (International
Electrotechnical Commission) 60529 “DEGREES OFPROTECTION PROVIDED BY ENCLOSURES (IP Code).”(IEC60529:2001)
IP68: Completely protected against dust. Protection against
submersion in water.
IP55: Protection against a level of dust that could hinder
operation or impair safety. Devices operate stably even when
directly exposed to water from any direction.

SANYO DENKI Technical Report No.39 pp. 9–12 (2015)(5) Naoya Inada and 5 others: G Proof Fans San Ace 120GP and San
Ace 172GP
SANYO DENKI Technical Report No.44 pp. 11–14 (2017)

Masato Murata
Joined SANYO DENKI in 1984.
Cooling Systems Div., Design Dept.
Works on the development and design of cooling
fans.

SANYO DENKI Technical Report No.46 November 2018

6

New Product Introduction

High Airflow Long Life Fan /High Airflow Long Life Splash Proof Fan
San Ace 140L and San Ace 140W
Masahiro Koike

Hiromitsu Kuribayashi

Koji Ueno

1. Introduction
With the growth of the IC T and renewable energy
markets, there is a demand for fans to have high airflow

Yasuhiro Maruyama

Osamu Nishikawa

2. Product Features
Figures 1 and 2 show the external views of the two newmodels.

and long life to support an increase in the internal heatgeneration of equipment.
Furthermore, in addition to offering high airflow and long
life, there is also a demand for fans to be waterproof to meetthe needs of ICT equipment and power condensers, which
are installed outdoors.
Also, from the perspective of protecting the environment,
there has been a sudden increase in demand for photovoltaic(PV) power generation, electric vehicles and so forth, thus
creating a need for highly reliable, long life, waterproof fansto support products such as quick charging stations.
SANYO DENKI had already manufactured and released
the 140 × 140 × 51 mm Long Life Fan and Splash Proof Fan.
In line with higher performance and higher efficiency of
ICT equipment and PV power systems in recent years, fansused in such equipment have been required to have evenlonger life and higher airflow.

Fig. 1 New model San Ace 140L

Even Splash Proof Fans are being required to offer higher
airflow and longer life in addition to sufficient waterproof
performance for outdoor equipment, such as PV inverters
and EV quick charging stations.
A m id such c i rc u m st a nc e s , SA N YO DE N K I h a sdeveloped and released two models: the High Airflow Long
Life Fan, San Ace 140L 9LG type, with an expected lifeof 180,000 hours, and the High Airflow Long Life Splash
Proof Fan, San Ace 140W 9WL type, with an expected lifeof 100,000 hours. This article introduces the features andperformances of these products.

Fig. 2 New model San Ace 140W

7SANYO DENKI Technical Report No.46 November 2018

High Airflow Long Life Fan / High Airflow Long Life Splash Proof Fan San Ace 140L and San Ace 140W

The new models maintain compatibility with the current
models in regard to fan size and mounting hole position,
while achieving higher airflow, longer service life, andgreater waterproof performance.

3. Product Overview
3.1 Dimensions
T he fans’ external dimensions and mounting hole

The features of the new models are:positions are unchanged from our current models. Figures 3(1) Dustproof/waterproof performance: Protection ratingand 4 show the dimensions of the new models.

IP68*(2) High airflow(3) Long life
(4) PWM control function
51±0.58-ø4.5±0.3（10）140±0.8
124.5±0.5

ROTATING DIRECTION

+30
300 0

AIRFLOWDIRECTION

4±0.2
6±0.4

124.5±0.5
140±0.8

4±0.2
6±0.4

Fig. 3 Dimensions of the San Ace 140L (unit: mm)
51±0.58-ø4.5±0.3（10）140±0.8
124.5±0.5

ROTATING DIRECTION

+30
300 0

AIRFLOWDIRECTION

124.5±0.5
140±0.8

4±0.2
6±0.4

4±0.2
6±0.4

Fig. 4 Dimensions of the San Ace 140W (unit: mm)

SANYO DENKI Technical Report No.46 November 20188

3.2 Expected life
The new model has an expected life of 180,000 hours with
the 9LG type and 100,000 hours with the 9WL type at 60°C
(survival rate of 90%, run continuously at rated voltage in

3.3 Characteristics
3.3.1 General specifications
Tables 1 and 2 show the general specifications of both newmodels.

free air and at normal humidity).

Table 1 General specifications for the new model San Ace 140L
Model no.

Max.
PWM
Rated
Rated Rated Rated Max. airflow
OperatingOperating Expected
static pressure SPL temperature
voltage voltage range duty cycle current input speedlife[dB (A)]
[%]
[V]
[A]
[V]
[W] [min-1] [m3/min] [CFM] [Pa] [inchH2O]
[˚C]
[h]

9LG1412P5G001
1210.2 to 13.8

9LG1412P5S001
9LG1424P5G001
24

20.4 to 27.6

9LG1424P5S001
9LG1448P5G001
48

40.8 to 55.2

9LG1448P5S001

100

5.16

62

7,500

9.0

318

655

2.63

69

20

0.31

3.72

2,300

2.75

97

80

0.32

38

100

1.83

22

5,000

6.0

212

295

1.18

57

20

0.31

3.72

2,300

2.75

97

80

0.32

38

100

2.58

62

7,500

9.0

318

655

2.63

69

20

0.16

3.84

2,300

2.75

97

80

0.32

38

100

0.91

22

5,000

6.0

212

295

1.18

57

20

0.16

3.84

2,300

2.75

97

80

0.32

38

100

1.29

62

7,500

9.0

318

655

2.63

69

20

0.12

5.76

2,300

2.75

97

80

0.32

38

100

0.45

22

5,000

6.0

212

295

1.18

57

20

0.12

5.76

2,300

2.75

97

80

0.32

38

-20 to +70

180,000/ 60˚C• Does not rotate when PWM duty cycle is 0%.
• PWM frequency: 25 kHz

Table 2 General specifications for the new model San Ace 140W
Model no.

Max.
PWM
Rated
Rated Rated Rated Max. airflow
OperatingOperating Expected
static pressure SPL temperature
voltage voltage range duty cycle current input speedlife[dB (A)]
[%]
[V]
[A]
[V]
[W] [min-1] [m3/min] [CFM] [Pa] [inchH2O]
[˚C]
[h]

9WL1412P5G001
1210.2 to 13.8

9WL1412P5S001
9WL1424P5G001
24

20.4 to 27.6

9WL1424P5S001
9WL1448P5G001
48
9WL1448P5S001

40.8 to 55.2

100

5.16

62

7,500

9.0

318

655

2.63

69

20

0.31

3.72

2,300

2.75

97

80

0.32

38

100

1.83

22

5,000

6.0

212

295

1.18

57

20

0.31

3.72

2,300

2.75

97

80

0.32

38

100

2.58

62

7,500

9.0

318

655

2.63

69

20

0.16

3.84

2,300

2.75

97

80

0.32

38

100

0.91

22

5,000

6.0

212

295

1.18

57

20

0.16

3.84

2,300

2.75

97

80

0.32

38

100

1.29

62

7,500

9.0

318

655

2.63

69

20

0.12

5.76

2,300

2.75

97

80

0.32

38

100

0.45

22

5,000

6.0

212

295

1.18

57

20

0.12

5.76

2,300

2.75

97

80

0.32

38

• Does not rotate when PWM duty cycle is 0%.
• PWM frequency: 25 kHz

9SANYO DENKI Technical Report No.46 November 2018

-20 to +70

100,000/ 60˚CHigh Airflow Long Life Fan / High Airflow Long Life Splash Proof Fan San Ace 140L and San Ace 140W

3.3.2 Airflow vs. static pressure
characteristics

12 VDC

900

F i g u r e 5 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r e

800

characteristics of the new models.
700（Pa）（inchH2O）

12/24/48 VDC

900

Static pressure［Pa］

3.5

800
3.0
700

Static pressure

2.5

2.0

1.5

G speed600

New models
9LG1412P5G001
9WL1412P5G001

600

500

2.7
times

400

300

500

Current models
9LB1412S501
9WB1412S501

200

400

100

S speed

1.1
times

300
0

1.0

1

2

200
0.5

0

0

4
5
6
7
Airflow［m3/min］

8

9

10

Fig. 6 Airflow vs. static pressure characteristicsof the new models San Ace 140L and San Ace 140W
in comparison with current models

100

0

3

1

2
50

3
100

4

5

6

150
200
Airflow

7
250

8

9
300

10（m3/min）
350（CFM）

Fig. 5 Airflow vs. static pressure characteristicsof the new models San Ace 140L and San Ace 140W

図版の文字

4.2 Comparison of expected life

123

Tables 3 and 4 give comparisons for the expected life
英語版用
Condens

and general specifications of the new models and current

英語版用models. The values shown are for the high performance
Times Tentypes of each model.

3.3.3 PWM control function
Both of the new models have a PWM control function and

Table 3 Comparison of the new model
San Ace 140L with the current model

are capable of high-speed control.

4. Comparison
with our Current Models
The following is a comparison of the characteristics of the
new and current models.

4.1 Comparison of airflow vs.
static pressure characteristics

Model no.

Expected life
[h]

Max.
airflow[m 3 /min]Max.
static pressure[Pa]

New model
9LG1412P5G001

180,000

9.0

655

Current model
9LB1412S501

60,0008.1

240Table 4 Comparison of the new model
San Ace 140W with the current model

Figure 6 provides an example of the airflow vs. staticpressure characteristics of the new and current models.

Model no.

Expected life
[h]

Max.
airflow[m 3 /min]Max.
static pressure[Pa]

New model
9WL1412P5G001

100,000

9.0

655

Current model
9WB1412S501

60,0008.1

240Compared to the current models, the new models havea 1.1 times greater maximum airflow and 2.7 times greater
maximum static pressure, thus offer an improvement inairflow vs. static pressure characteristics.

SANYO DENKI Technical Report No.46 November 201810

Both the 9LG and 9WL type models offer improved
airflow vs. static pressure characteristics, yet the 9LG typehas an expected life (with 60˚C ambient temperature, 90%
survival rate, run continuously at rated voltage in free air
and at normal humidity) of 180,000 hours, which is 3 times
greater than the 60,000 hour lifespan of current models.
The 9WL type has an expected life of 100,000 hours, whichis 1.7 times greater than the 60,000 hour lifespan of current
models.

Current model

New model

Fig. 8 Impeller shape comparison of the current
and new models

5. High Airflow/Long Life
and Waterproof Performance
Technologies

5.2 Frame

The new models were designed to be waterproof while

For the frame, we used aluminum die-cast as the material

offering both an airflow and lifespan surpassing that of theand adopted a design whereby the frame was integrated withcurrent models.

the bearing house. By newly developing the frame spoke

For the new models, the impeller shape and frame were
optimized to achieve higher airflow, and an aluminum

shape, airflow efficiency was improved, thus achieving
higher airflow and higher static pressure.

die-cast frame was adopted for longer life. The following

Furthermore, the aluminum die-cast frame surface has

sections briefly introduce the design points contributing tobeen coated to protect it from corrosion due to rust, etc. as ahigher airflow and longer life on the new models comparedresult of exposure to external environments. This has madeto the current models.

it possible to use the fans for a prolonged period of time evenin environments where it is splashed with water.

5.1 Impeller shape

Figure 9 shows a frame shape comparison of the current

We newly developed t he i mpel ler a nd adopted aand new models.

structure with an intake route in order to suppress bearing/motor temperature. (Fig. 7) Moreover, we improved thenumber and angle of blades and achieved higher airflow
by improving airflow efficiency, thus minimizing power
consumption. Figure 8 shows an impeller shape comparisonof the current and new models.

Current model

Air Air
intakeintakeCurrent model

New model

Fig. 7 Impeller cooling structure of the current
and new models

11

SANYO DENKI Technical Report No.46 November 2018

New model

Fig. 9 Frame shape comparison of the current
and new models

High Airflow Long Life Fan / High Airflow Long Life Splash Proof Fan San Ace 140L and San Ace 140W

5.3 Drive motor
For the Splash Proof Fan, to prevent breakdowns due towater penetration, we have coated the live parts (motor,
control circuit) in resin, as shown in Figure 10.
Furthermore, in order to achieve a dustproof/waterproof* Shows the protection rating for the San Ace W series.
The protection rating (IP code), is defined by IEC (International
Electrotechnical Commission) 60529 “DEGREES OFPROTECTION PROVIDED BY ENCLOSURES (IP Code).”(IEC60529:2001)
IP68: Completely protected against dust. Protection against
submersion in water.

performance rating of IP68*, the below structure wasadopted.

Reference(1) Live parts (motor, control circuit) protected with highly(1) Kakuhiko Hata and others: High Airflow, High Static Pressure

waterproof material (Fig. 10).
(2) M agnets made from material with excellent water
resistance compared to the material normally used forfans.
(3) Rustproofing applied to the necessary areas.

Splash Proof Fan San Ace W
SANYO DENKI Technical Report No. 32 pp. 20-24 (2011-11)(2) Katsumichi Ishihara and others: High Airflow Long Life Splash
Proof Fan San Ace W
SANYO DENKI Technical Report No. 38 pp. 20-25 (2014-11)

The new models are faster than the current models so thedrive motor was enlarged to improve motor efficiency.
T h i s h a s m ade it p o s sible to ach ieve low p ower
consumption and, regardless of the live parts being coatingin resin, reduce the heat generated by the motor coil, thus

Masahiro Koike
Joined SANYO DENKI in 2006.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

minimizing bearing temperature rise.

Hiromitsu Kuribayashi
Joined SANYO DENKI in 1996.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Koji Ueno
Joined SANYO DENKI in 2001.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Yasuhiro Maruyama
Fig. 10 Coating condition of live parts

6. Conclusion
This paper has introduced some features and performanceof the High Airflow Long Life Fan and High Airflow Long

Joined SANYO DENKI in 2001.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Osamu Nishikawa
Joined SANYO DENKI in 2009.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Life Splash Proof Fan, San Ace 140L and San Ace 140W.
Both new models offer higher airflow and longer service
life. As such, they contribute toward maintenance-freefans for adoption in indoor/outdoor equipment and help toreduce fan replacement frequency (no. of units).
With today’s diversifying global market, we believe thisdevelopment contributes significantly to optimal coolingsolutions.

SANYO DENKI Technical Report No.46 November 201812

New Product Introduction

High Static PressureLong Life Counter Rotating Fan
San Ace 60L 9CRLA Type
Yoshihisa Yamazaki

Haruhisa Maruyama

Seiji Takeuchi

1. Introduction

Yusuke Okuda

Honami Osawa

counter rotating fan, San Ace 60L 9CRL type, however we
recognized the need to improve static pressure performanceWith the rapid shift to high-performance ICT equipment

in order to realize even higher cooling performance.

in recent years, there is a greater requirement for the high-In response to such a requirement, we newly developed

density design of such equipment, further increasing heatand launched the high static pressure long life counter

generation. Amid such market trends, many customers

rotating fan, San Ace 60L 9CRLA type (hereinafter, “neware adopting counter rotating fans, and there is a demandmodel”).
This article will introduce the features and performancefor such fans to offer even higher cooling performance.
C ustomers a lso requ i re equ ipment w ith longer l i feof the new model.

expectancy, giving rise to a demand for long-life fanswith high cooling performance. SANYO DENKI had
already developed and launched the high static pressure

2. Product Features
Figure 1 shows an external view of the new model.
The features of the new model are:(1) High static pressure(2) Long life(3) Low power consumption

3. Product Overview
Fig. 1 60 × 60 × 76 mm San Ace 60L 9CRLA type

3.1 Dimensions
Figure 2 shows the dimensions of the new model.

Inlet
4-ø4.3±0.3
Mounting hole4±0.3

76±0.54±0.3

60±0.550±0.350±0.3

+50
300 0
(10)

Lead wire
AWG 26
UL 1430
(10)
+50
300 0
Rotating direction

Airflow direction

Fig. 2 Dimensions of the new model (unit: mm)

134-ø4.3±0.3
Mounting hole

SANYO DENKI Technical Report No.46 November 2018

Rotating direction

60±0.5

OutletHigh Static Pressure Long Life Counter Rotating Fan San Ace 60L 9CRLA Type

Table 1 General specifications for the new model
Operating
Max.
PWM
Rated
Rated Rated Rated speed
OperatingMax. airflow
voltage
SPL
static pressure[min-1]duty cycle current input
Model no.
voltagetemperaturerange[dB (A)]
[%]
[V]
[A]
[W]
[˚C]
Inlet Outlet [m 3/min] [CFM] [Pa] [inchH2O]
[V]
10.8
-20
100
3.0
36.0 16,500 17,800 2.1
74.1 1,400 5.62
70
9CRLA0612P0G001 12
to
to
20
0.4
4.8 5,000 5,400 0.64 22.6 128 0.51
43
13.2
+70

Expected
life[h]100,000/ 60˚C

4. Key Points of Development

3.2 Characteristics
3.2.1 General specifications
Table 1 shows the general specifications for the new model.

The new model features a newly-designed impeller
and frame which improves static pressure. Moreover, we

3.2.2 Airflow vs. static pressure
characteristics

increased rotational speed, which is effective in improving
static pressure performance, and increased the impeller

F i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r estrength accordingly.
The key points of development are explained below.

characteristics for the new model.

3.2.3 PWM control function

4.1 Impeller and frame design

The new model has a PWM control function that enables
external control of fan speed.

For the new model, there was a need to improve theoverall static pressure performance in terms of airflow
vs. static pressure characteristics. Generally speaking,

3.3 Expected life

increasing impeller rotation speed makes it possible to

The new model has an expected life of 100,000 hours at

improve static pressure performance. As such, we attempted

60°C (survival rate of 90%, run continuously at rated voltage

increasing rotational speed compared to the current modelin free air and at normal humidity).

for this new model, however this created the issue of higher
power consumption.

（inch H2O）（Pa）

12 VDC

1600
6
PWM duty
100%

1400
5

Figure 4 shows a dynamic blade shape comparison of thecurrent and new models.
Figure 5 shows the flow of air of the new model.

1200
図版の文字

Static pressure

4

123

1000

英語版用

3

Condens

800

英語版用

Times Ten
600

Inlet

Inlet

OutletOutletCurrent model

New model

2
400
1

0

PWM duty
20%

200

0
0

0.5
10

20

1
30

1.5
40

50

2
60

70

2.5（m3/min）
80 （CFM）

Airflow

Fig. 3 Airflow vs. static pressure characteristicsof the new modelFig. 4 Dynamic blade shape comparisonof current and new models

SANYO DENKI Technical Report No.46 November 201814

To resolve this issue, we leveraged fluid analysis to design

4.2 Integrated type

optimal shapes for the dynamic and static blades, andWith increased fan rotational speed, impellers require

reduce power consumption. Figure 4 shows a comparison

a structure that can withstand high rotation. As such, weof the shapes of the current and new models. The dynamic

employed a structure that integrated the impeller andblades straightened the wind flow. By changing the shaperotor cover. By increasing joint strength, the impeller canin this way, we increased impeller efficiency comparedwithstand high rotation.

to the dynamic blades of the current model, and reduced
the load torque of the dynamic blades, increasing theimpeller’s rotational speed. Figure 5 shows the airflow of
the new model. Flow lines are used to indicate the airflow
across the surface of the dynamic and static blades, and it is

5. Comparison with Current Model
5.1 Comparison of airflow vs.
static pressure characteristics

apparent that the air flows smoothly along the blade profile.

Compared to the cur rent model, the new model’sMoreover, the figure expressing airflow speed distribution

maximum airflow has increased by 5%, and its maximum

demonstrates the straightness of the airflow.

static pressure has increased by 40%.

Through this optimization of the dynamic and static
blades, we succeeded in significantly increasing static

Figure 6 provides an example of the airflow vs. staticpressure characteristics of the current and new models.

pressure performance and achieved our high static pressure
and low power consumption targets. Moreover, by reducing

1600

power consumption, we were able to suppress the amount of

Voltage: 12 V
PWM Duty：100%

heat generated by the motor, enabling longer service life.

New model
9CRLA0612P0G001

1400

1200

Static blade

40% up

Airflow direction
Static pressure [Pa]

1000

800

Current model
9CRL0612P0G001

600

400

200

5% up
Airflow across surface of dynamic and static blades

0
0

0.5

1

1.5

2

2.5

Airflow [m /min]3

Fig. 6 Airflow vs. static pressure characteristics
of current and new models

Wind speed distribution of the new model

5.2 Power consumption comparison
Figure 7 gives a comparison of the power consumptions
for the airflow vs. static pressure characteristics of theFig. 5 Airflow of the new model

図 6 both have equivalentcurrent and new models whenmaximum static pressure.
This graph compares the airflow vs. static pressure

15

SANYO DENKI Technical Report No.46 November 2018

High Static Pressure Long Life Counter Rotating Fan San Ace 60L 9CRLA Typecharacteristics when the rotational speed of the new model

Yoshihisa Yamazaki

is reduced, and the maximum static pressures are equivalent

Joined SANYO DENKI in 2016.
Cooling Systems Div., Design Dept.
Works on the development and designof cooling fans.

for both the new and current models. It is evident that,
overall, the new model has lower power consumption thanthe current model, and we have succeeded in reducing power
consumption by 20% in the vicinity of maximum static

Haruhisa Maruyama

pressure.

Joined SANYO DENKI in 1997.
Cooling Systems Div., Design Dept.
Works on the development and designof cooling fans.

1600

40

1400

35

-20%

30

1000

25

800

20

600

15

Voltage: 12 V
PWM frequency: 25 kHz

400

10

Current model

200

Joined SANYO DENKI in 2006.
Cooling Systems Div., Design Dept.
Works on the development and designof cooling fans.

Power consumption [W]Static pressure [Pa]1200

Seiji Takeuchi

Yusuke Okuda
Joined SANYO DENKI in 2010.
Cooling Systems Div., Design Dept.
Works on the development and designof cooling fans.

Honami Osawa
Joined SANYO DENKI in 1989.
Cooling Systems Div., Design Dept.
Works on the development and designof cooling fans.

5

9CRL0612P0G001
New model(PWM DUTY 80%)
9CRLA0612P0G001

0

0
0

0.5

1

1.5

2

Airflow [m3/min]Fig. 7 Example of the airflow vs. static pressure
characteristics (comparison with current model)

6. Conclusion
This article has introduced some of the features and
図 7

performance of the 60 × 76 mm high static pressure long life
counter rotating fan San Ace 60L 9CRLA type, developedby SANYO DENKI.
The new model offers longer service life at the same time
as significantly higher static pressure.
As such, we believe it will significantly contribute to thecooling of high heat-generating, high-density equipment, forwhich demand will continue to increase.
SANYO DENKI wishes to continue developing products
responding to market needs and offering products which
contribute to creating new values for our customers.

SANYO DENKI Technical Report No.46 November 201816

Feature: Technologies Creating Change

Development of UPS Products Equippedwith Lithium-Ion Batteries Creating
Change and Offering New Value
Masahiko Nagai

1. Introduction

broadening the scope of UPS utilization, creating change inthe market, and offering new value.

SANYO DENKI develops and releases uninterruptible

The features of these UPS models are (1) a wide operating

power supplies (UPS) to protect important equipment suchtemperature range that can be used with peace of mind

as servers and ICT equipment in the event of power outages.

in both extremely cold and extremely hot regions, (2)Conventionally, lead-acid batteries have been used insignificantly smaller size than SANYO DENKI’s current

UPSs due to their lower cost and ease of use. Lead-acidmodels, and (3) reduced battery replacement costs bybatteries are excellent in terms of availability, safety, andextending the battery replacement interval from five to ten

cost. However, lead-acid batteries and the UPSs which use

years.

them have the following problems.

Moreover, the safety of these UPSs have been improved(1) ‌The characteristics and lifespan of lead-acid batteries are

by monitoring LIB information on the UPS side, in addition

easily affected by operating temperature, so they needto the management system on the LIB side. The following

to be installed in temperature-controlled environments.

sections will introduce SANYO DENKI’s LIB-equipped

For example, if the average operating temperature is

UPS product lineup.

25˚C, the lower the temperature falls below this, thesmaller the battery capacity becomes, reducing UPS
backup time. Moreover, in environments above 25˚C,battery life shortens relative to the temperature.

2.1 SANUPS A11K-Li series
The SANUPS A11K-Li series are LIB-equipped UPSs
which adopt the highly reliable double conversion online(2) ‌In the case of lead-acid batteries, generally the capacity

topology, and are suitable for backup of computers andat the end of battery service life is set at 50% of the

production equipment. They are space-saving, and offer

initial value, so UPS backup time is shorter when aextended backup time.

battery nears the end of its life. Moreover, service life is

The lineup is available with output capacities of 1.5, 3, andshortened if there is a high charge/discharge frequency.

5 kVA. Figure 1 is an external view of the SANUPS A11K-

As such, the battery must be replaced at an early stage to

Li series. All models can be installed in 19-inch racks.

ensure load equipment will be properly backed up in theevent of a power outage.
(3) ‌Lead-acid batteries have a relatively small energy
density, so if a UPS requires prolonged backup time, thenumber of batteries must be increased, therefore a large
installation space must be secured.

2. UPSs Creating Change
in the Market
SANYO DENKI solved these problems of UPSs using
lead-acid batteries by developing UPSs equipped withlithium-ion batteries (hereinafter LIBs) that can be installedin harsh environments that were previously impossible,

17

SANYO DENKI Technical Report No.46 November 2018

Fig. 1 SANUPS A11K-Li (1.5 kVA)Development of UPS Products Equipped with Lithium-Ion Batteries Creating Change and Offering New Value

2.2 SANUPS N11B-Li series

Monitoring systems for disaster management facilities are

In recent years, there has been an increasing demand for

installed in confined spaces such as small-scale unmanned

backup power for outdoor facilities such as base stations,buildings or containers, with no form of air-conditioning;

traffic lights, paid parking lots, and surveillance cameras.

therefore, it is assumed that they will be required to operate

Hence, SANYO DENKI developed the SANUPS N11B-

in harsh environments. As such, UPSs are required to

Li series, which can be used outdoors due to having a designoffer high-efficiency, long backup times, space-saving, lowwhere the UPS main unit and LIB are housed in a single

maintenance, and have a wide operating temperature range.

enclosure with IP65* dustproof and waterproof protection.

To meet these needs, SANYO DENKI developed theThis product is available with output capacities of 1, 1.5,

SANUPS N11C-Li series which features a small footprintand 3 kVA. Figure 2 is an external view of the SANUPS

and adopts the passive standby topology with minimal heatN11B-Li series.

dissipation.

This UPS adopts a passive standby topology to minimize
power consumption and achieve high efficiency. This makes

This product is available with output capacities of 1.5, 3,
and 5 kVA.

it possible to install the UPS outdoors where the ambient

With minimal heat dissipation and high-efficiency, it

temperature is high, as well as helps to reduce running costs

can be used in extreme temperature environments, such as

and save energy.

outdoor cubicles without air-conditioning, and contributes
to lower running costs and energy-saving.

*The degree of protection (IP code) is defined by IEC(International Electrotechnical Commission) 60529 “DEGREESOF PROTECTION PROVIDED BY ENCLOSURES (IP Code)” (IEC60529:2001)
IP65: No ingress of dust. Devices operate stably even when
directly exposed to water from many directions.

Figure 3 is an external view of the SANUPS N11C-Li
series. All models can be installed in 19-inch racks.

Fig. 3 SANUPS N11C-Li (5 kVA)

3. Common Featuresof the Newly Developed UPSs
The above-mentioned UPS products share common
features that offer new value. These features are described
below.

3.1 Low maintenanceFig. 2 SANUPS N11B-Li series

Conventional lead-acid battery-equipped UPSs have to be
replaced approximately every five years. The expected lifeof the LIBs used in these UPSs is ten years, which means

2.3 SANUPS N11C-Li series

no battery replacement work is required for approximately

T here is a demand for backup power for disasterten years. The expected life of the UPS main unit is also ten

management facilities such as floodgates, warning sirens,

years, so no maintenance work, such as battery replacement,

and emergency management radios as well as for the system

is required during this period, meaning that maintenancepower source that monitors them.

and operating costs are reduced.

SANYO DENKI Technical Report No.46 November 201818

3.2 Wide operating temperature range
LIB-equipped UPSs have an operating temperature range
between -20˚C and +50˚C or 55˚C, which is wider than that of

4. Technology Achieving High Safety
and Offering Peace of Mind
4.1 LIB protection function

conventional models.
By widening the operating temperature range we have

Due to the high energy density of LIBs, there is somesignificantly expanded the scope of UPS application, so

concern about smoke and fire. But by carefully monitoring

they can now be used in harsh temperatures, which was

LIB status, they can be used safely.

previously impossible with conventional UPSs.

SANYO DENKI’s LIB-equipped UPSs feature safety
management of LIB with a battery management system

3.3 Compact and lightweight(BMS), as well as monitor the LIB on the UPS to protect

Compared to lead-acid batteries, LIBs have higher energy

the LIB in the event of an abnormality being detected.

densities. When comparing products with equivalent backup

Overviews of these protection functions are as follows.

times, LIB-equipped UPSs are around half the volume(1) Protection‌by BMSand mass of conventional UPSs. Figure 4 illustrates the

BMS monitors LIB current, cell voltage, and cellconfiguration differences between UPSs using lead-acidtemperature, and turns the switch off to disconnect andbatteries and UPSs using LIBs.

protect the LIB if it detects an overcurrent, overcharge,

The LIB-equipped UPS occupies less space than the leadacid battery UPS, contributing to efficient usage of space inor excessive temperature.
(2) ‌Protection by UPS
A UPS communicates with the BMS and monitors

the locations in which they are installed.

LIB status during operation. If a communication error
UPS with lead-acid batteries(A11K 1.5 kVA,
180-minute configuration)

UPS body

UPS with LIBs
(A11K-Li 1.5 kVA,
200-minute configuration)

occurs, the UPS stops charging to protect the LIB. Also,
if the LIB’s charging voltage or cell voltage increases, the
UPS stops the charger to protect the LIB. Furthermore,
the UPS stops charging or discharging if the LIB’s celltemperature becomes too high.

Lead-acidbatteries

If any other abnormality occurs in the UPS or LIB, thecircuit is disconnected on both UPS and LIB-side switches
LIBs

Li-ion20

for protection. Moreover, in the event of a short circuit, the
LIB is isolated via a fuse to protect wiring.

Rack capacity: 17 U
Mass: Approx. 266 kg

Rack capacity: 10 U
Mass: Approx. 124 kg

Figure 5 shows how the UPS and LIB configure theprotection.

Fig. 4 Comparison of UPS configurations(when mounted in a 19-inch rack)
ChargerTable 1 compares the features of an LIB-equipped UPS
with a conventional lead-acid battery-equipped UPS.

UPS

SwitchControl unit
Fuse

Table 1 Features of the newly developed UPS

Expected
battery life

Conventional UPS(with lead-acidbatteries)

Newly developed
UPS(with LIB)

5 years*

10 years*(ambient temperature:
25˚C)(ambient temperature:
30˚C)

Operatingtemperaturerange-10 to 40˚C

-20 to 55˚C

Volume, mass

1

Approx. 1/2*: Assuming ten power outages a year

19

SANYO DENKI Technical Report No.46 November 2018

Communication
Fuse
LIB

SwitchBMS

CellFig. 5 LIB protection functions

Development of UPS Products Equipped with Lithium-Ion Batteries Creating Change and Offering New Value

4.2 Optimal device internal layout
Conventionally, UPSs are mostly installed indoors.

5. Conclusion

However, as described above, we designed the SANUPSThis article has introduced new UPS products equipped

N11B-Li to be used outdoors, which required a protection aswith LIBs and the technologies that we used to realize theirhigh as IP65.

performance.

The heat generated within an IP65 rated enclosure cannot

These products and technologies broaden the scope of

directly escape to the outside. If heat is trapped inside the

UPS application as they enable UPSs to back up equipment

UPS and becomes concentrated in one area, it may raise thein harsh environments, which was previously impossible

temperature of the electronic components or LIB, whichwith conventional products. Moreover, by not requiringin turn could hasten component deterioration or trigger

battery replacement for approximately ten years, thesea malfunction. In such cases, the UPS may not reach its

products help to reduce maintenance costs.

expected life, possibly leading to a fail in backing up loadequipment properly.
With consideration to this aspect, in designing the UPS,

We will continue to pursue technologies that broaden
UPS applications and create major market changes, anddevelop products that offer our customers new value.

SANYO DENKI used a thermal fluid analysis simulation
to verify internal heat flow, and optimized the structure andlayout design to effectively circulate and discharge heat to

Masahiko Nagai

the outside by using the entire enclosure. Figure 6 shows one

Joined SANYO DENKI in 1993.
SANYO DENKI PHILIPPINES, INC.
Works on the development and design of UPS
and PV power systems.

example of thermal fluid analysis.
As a result, we succeeded in designing an enclosure withan IP65 protection without reducing UPS performanceand reliability by preventing heat from concentrating inparticular spots, thus developing a UPS with high reliability
capable of operating outdoors.

Fig. 6 Thermal fluid analysis modelof the SANUPS N11B-Li (3 kVA)

SANYO DENKI Technical Report No.46 November 201820

New Product Introduction

Development of the Small-Capacity
UPS SANUPS N11C-Li Series
Shota Ozawa

Shinichiro Yamagishi

Hideaki Yoda

Yasuhiko Ogihara

Hirofumi Kimura

Yuhei Shoyama

Takeo Murai

Kazuya Yanagihara

Hiroyuki Saito

Kazuya Hiraguri

Shota Takahashi

1. Introduction
Uninterruptible Power Supplies (UPSs) are used forbacking up disaster management facilities such as floodgates
and warning sirens. As such, they are installed inside small
unmanned buildings, cubicles, or containers, therefore must
operate in extreme temperatures.
For this reason, UPSs are required to be space-saving,
maintenance-free, have a wide operating temperature range,

2. Product Overview
The SANUPS N11C-Li is available in three models with
1.5, 3, and 5 kVA output capacities.
Figures 1 (1) through (3) show an appearance of eachmodel.
All the models are designed compatible with battery
expansion as shown in Figure 1 (4) and mountable on a rackas shown in Figure 1 (5).

and offer prolonged backup. Moreover, these small-scalebuildings often have no form of air-conditioning; therefore
UPSs for these applications must be highly efficient andhave reduced heat dissipation so as not to increase thetemperature inside and affect equipment.

3. Features
3.1 Wide operating temperature range
Ado pt ion of L I B h a s en able d a w id e o p er at i n g

The lead-acid batteries that have conventionally been

temperature range of -20 to +55˚C. The SANUPS N11C-Li

adopted in small-capacity UPSs have a limited operating

can be used in extremely hot and cold regions, inside small

temperatu re ra nge, therefore requ i res replacement

unmanned buildings without air-conditioning, and the like.

approximately every five years. Moreover, to achieve
prolonged backup, more batteries are needed, which in turnrequires more installation space.

3.2 Maintenance-free
While our conventional UPSs with lead-acid batteriesCompared with U PSs with conventional lead-acidrequire battery replacement approximately every fivebatteries, however, ones with lithium-ion batteries (LIB)

years, this UPS, thanks to the employed LIB, can operate

can be used in a wider operating temperature range, require

for roughly ten years without battery replacement. Thisless space, offer long backup time, and operate withoutmaintenance-free operability reduces battery replacement

maintenance.

costs.

Our UPS products using LIB include the SANUPS
A11K-Li, a double conversion online UPS for indoors

3.3 Improved maintainability

and SANUPS N11B-Li, a standby UPS for outdoors.

Works such as battery replacement have been made easy

We expanded this lineup with the addition of the SANUPS

through the modularization of the inverter. Figure 2 shows

N11C-Li that can be used inside small unmanned buildings

how an inverter module and battery modules are installed in

or in other extreme temperature environments. This article

the SANUPS N11C-Li.

introduces the features of this new model.

All the models have a maintenance bypass circuit;therefore, module replacement and other maintenance work
can be performed with the grid power supply continued.

21

SANYO DENKI Technical Report No.46 November 2018

Development of the Small-Capacity UPS SANUPS N11C-Li Series

3.4 Improved functionality
An LCD panel is used on the operation panel to improveuser-friendliness and visibility.

3.5 Compact and lightweight
UPSs with LIB are around half the volume and mass of
conventional UPSs with lead acid batteries, provided that(1) 1.5 kVA

both have equivalent initial backup time.

3.6 Energy saving and reduced heatdissipation
With the passive sta ndby topolog y, the SA N UPS
N11C-Li suppresses power consumption and achieves a
conversion efficiency of 95%. This reduces running costs
and contributes to energy saving. Furthermore, because(2) 3 kVA

it does not generate much heat, the temperature increasein small-scale buildings with no air-conditioning can be
minimized.

3.7 Extended LIB installation
By installing additional LIB, even longer backup time canbe realized.
* (Max. of 400 minutes for 1.5 kVA model)(3) 5 kVA

3.8 Rack-mountable
This UPS can be mounted on a 19-inch rack (EIA
standard), therefore can easily be built into indoor equipment.

4. Circuit configuration
Figure 3 shows the circuit diagram for the SANUPS N11C-Li.
The SANUPS N11C-Li comprises a power supply unit
(4) Battery expansion(1.5 kVA)(5) Rack-mount (1.5 kVA)

consisting of a main circuit, control circuit, communicationinterface circuit, and other components, and battery unit

Fig. 1 SANUPS N11C-Li seriesconsisting of a battery module, battery management unit
(hereinafter BMU), and other components.

Inverter module

4.1 LIB monitoring circuit configuration
Equipped with a BMU, this product features a datainterface between the UPS and LIB. The safety of the
UPS has been increased by monitoring detailed LIB dataand performing mutual protective operations and fault
detections between UPS and LIB,
(1) UPS‌error detection
A UPS error will be notified by the UPS to BMU

Battery module

Fig. 2 Inverter module and battery modules(SANUPS N11C-Li 1.5 kVA)

via CAN communication. After notified, the BMU
disconnects the UPS and LIB.
(2) ‌LIB error detection
An LIB error will be notified by the BMU to the UPS
via CAN communication. In response, the UPS stops the

SANYO DENKI Technical Report No.46 November 201822

charger’s output. Moreover, if the BMU detects an LIB

cell becomes over-charged, over-discharged, or reaches

error, it will disconnect the UPS and LIB.

an abnormal temperature, the BMU determines thatan LIB error has occurred, and isolate the UPS from(3) ‌Monitoring LIB cell voltage and cell temperature

the LIB.

Cell voltage and temperature are measured in theUsers can check the measured values of battery voltage,battery module, and the measurement values are thencell temperature, and state of charge on the LCD panel.

notified to BMU through CAN communication. If theMaintenance bypass circuit
Grid power circuitaElectronic
switchNote 1

FilterFuse

FilterAC input

Inverter

RectifierAC output

DC/DC
converter

G

Control

12 VDC+12 V
power supply

FE

Interface

Fuse

Invertermodulea

LAN interface(optional)b

Contact
interface(optional)

Power supply unit

PC I/FCARD I/F
CHG I/F
BATT I/F
SIGNAL│REMOTE** Connect to CARD I/F* (Either one)

Battery connector
EXT. BATTERY

FE

12 VDCUPS I/F IN

Relay board

CMU
Battery
connector
UPS EXT.
BATTERY

Battery Current
breaker sensor

Main battery unit

BMU

Fuse

CMU

Battery module

External battery connector
EXT. BATTERY

Note 1: For the SANUPS N11C-Li 3 kVA and 5 kVA models, output power is available from both the output power outlet and terminal block.

Fig. 3 Circuit diagram for the SANUPS N11C-Li (1.5 kVA)

23

SANYO DENKI Technical Report No.46 November 2018

Development of the Small-Capacity UPS SANUPS N11C-Li Series

5. Specifications
Table 1 shows the standard specifications of the SANUPS
N11C-Li.

Table 1 Specifications of the SANUPS N11C-Li
Item
Model
Rated power capacity
UPS topology
Cooling method
Type
Inverter system

AC
input

−

kVA/kW−−−−

Ratings and characteristics
N11CL152 N11CL302 N11CL502
1.5/1.2
3.0/2.4
5.0/4.0
Passive standby
Forced air coolingHigh-frequency PWM method(during battery operation)
Single-phase 2-wire
100, 110, 120
Within ±10 of rated voltage
50/60
Within ±1, 3, 5, or 7of rated frequency

No. of phases/wires
Rated voltage
Voltage range
Rated frequency

V%
Hz

Frequency range%

Required capacitykVA

2.1 max.

No. of phases/wires
Rated voltage−

Voltage regulation%

Rated frequency

Hz%

Single-phase 2-wire
100, 110, 120
During grid operation:
Same as input voltage range
During battery operation:
Within ±2 of rated voltage
During grid operation:
Same as input voltage range
During battery operation: 50/60
During grid operation:
Same as input voltage range
During battery operation:
Within ±0.5 of the rated frequency
3 or less / 7 or less%Within ±7 of rated voltage%

Within ±5 of rated voltage−

0.8 (lagging)
105 or greater
105 or greater
200/800
Lithium-ion battery (LIB)
50/100/30/60/
100/200/
300/400
150/200
90/120AC
Frequency regulation
outputBattery

Unit

Voltage harmonic distortion
Rapid load
Transientchangevoltagefluctuation Loss or returnof input power
Load power factor
Overcurrent protection
Inverter
Overload
capability Bypass
Type
Backup time

Acoustic noise

Operatingenvironment
Storageenvironment

V

%

%
%
−

Minute4.0 max.

6.7 max.

45 max.

46 max.

46 max.

51 max.

55 max.

55 max.(1)dB

Ambient temperature
Relative humidity
Ambient temperature
Relative humidity

˚C
%
˚C
%

-20 to +55
10 to 90
-20 to +55
10 to 90

Remarks
Apparent power / active power

Grid synchronous double conversion online
Same as output voltage
Frequency is automatically detected(The fluctuation range is the sameas the selected output frequency regulation)
Max. capacity during battery recovery
charging
Voltage waveform: Pure sine wave

At rated output

At rated output
Linear load/rectifier load, at rated output
During battery operation, for 0 ⇔100% load
step changes / At output switch
During battery operation, at rated output
Variation range: 0.7 (lagging) to 1.0
Automatic transfer to bypass
200 ms
30 s / 2 cycles
Ambient temperature 25˚C, at rated output,
under factory conditions
1 m from front of device, A-weighting(Where the ambient temperature is 40˚C orlower)
1 m from front of device, A-weighting(Where the ambient temperature exceeds
40˚C)
(2)

Non-condensing(3)

Non-condensing

60 dB or less when battery voltage drops.
(2) Battery charging stops when battery temperature exceeds 55˚C.
(3) To extend battery life, avoid storage for extended periods of time in environments exceeding +30˚C. If the UPS is stored without being
operated for a long period, the batteries may require recharging once a year.
(1)

SANYO DENKI Technical Report No.46 November 201824

Development of the Small-Capacity UPS SANUPS N11C-Li Series

6. Conclusion
This article has introduced the SANUPS N11C-Li series
as a new UPS with LIB.

Yuhei Shoyama
Joined SANYO DENKI in 2009.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

With the features of a wide operating temperature range,
maintenance-free operability, compact size, and high-Takeo Murai

efficiency, this product can create new UPS markets such

Joined SANYO DENKI in 2012.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

as installation in small unmanned buildings and indoor
equipment without air-conditioning.
With UPSs becoming increasingly important to society
and their applications and installation environments

Kazuya Yanagihara

diversify, UPSs that are even more compact and have longer

Joined SANYO DENKI in 2013.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

backup time will be required. We will expand our productlineup of UPSs with LIB to meet these market needs,
aiming to develop products that can provide our customers
with new value.
Reference(1) Yuhei Shoyama and others: Development of the Small-Capacity

Hiroyuki Saito
Joined SANYO DENKI in 2015.
Power Systems Div., Design Dept.
Works on the mechanism and design of UPS.

UPS SANUPS A11K-Li and SANUPS N11B-Li Series
SANYODENKI Technical Report No. 44(2) Takeo Murai and others: Development of the SANUPS N11B-Li (3kVA) Uninterruptible Power Supply
SANYODENKI Technical Report No. 45

Joined SANYO DENKI in 2016.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

Shota Ozawa

Shota Takahashi

Joined SANYO DENKI in 2014.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

Joined SANYO DENKI in 2017.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

Shinichiro Yamagishi
Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

Hideaki Yoda
Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

Yasuhiko Ogihara
Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept.
Works on the mechanism and design of UPS.

Hirofumi Kimura
Joined SANYO DENKI in 2007.
Power Systems Div., Design Dept.
Works on the development and design of UPS.

25

Kazuya Hiraguri

SANYO DENKI Technical Report No.46 November 2018

Feature: Technologies Creating Change

Servo System Technologies Creating
Monozukuri Changes
Hideaki Kodama

Yasutaka Narusawa

Norio Nakamura

1. Introduction

Shusaku Magotake

robot posture with ease.
Robot posture can be controlled simply by setting the typeI n rec ent yea rs, it ha s bec ome nec essa r y for theof robot to be developed, arm length, and gear ratio. Posture

manufacturing industry to both improve productivity andcontrol does not require complicated calculations, therefore

increase flexibility toward market changes and fluctuation.

the burden of program development placed on customers is

As such, many manufacturers are undertaking major change

reduced.

by incorporating ICT technologies for robot automation,etc. and information technologies, such as IoT and AI, in an
attempt to achieve advanced monozukuri.
This article will introduce technologies that support
robot development, and servo system monitoring functions
and ICT technologies as servo system technologies thatcreate monozukuri change. This article will also provide
examples of our production line initiatives which use thesetechnologies.

2. Robot Development Support
Technologies
An effective way to increase monozukuri productivity
and flexibility is to use robots to automate processes thatwere conventionally done by humans. However, there are anumber of issues involved in developing a production systemthat uses robots, such as training personnel to have robot
expertise and prolonged development periods.
I n order to solve such i s sues, SA N YO DE N K I’s
SANMOTION C Controller (1) features technologies andFig. 1 Robot mechanism setting tool

functions supporting robot development, and these are
introduced below.
SANMOTION C features an abundance of technologies

2.2 Teaching/program function

enabling the development of robot operation programs

As Figure 2 shows, SANMOTION C features a teachingeasily and quickly, namely, robot posture control, apendant to easily program robot operations. Wizard-styleteaching/program function, and a simulation function.

screens such as that shown in Figure 3 simplify the process

Below are explanations about each technology.

of setting complex robot hand positions. Moreover, thecommands shown in Table 1 have been prepared to achieve

2.1 Robot posture control
For SANMOTION C, we have prepared a mechanism

robot operations with ease. These functions make it possible
to program robot operations in a short period of time.

setting tool, as per Fig. 1, which makes it possible to control

SANYO DENKI Technical Report No.46 November 201826

2.3 Operation simulation
SANMOTION C offers software that can simulate robot
operations.
This software makes it possible to confirm whether the
robot is operating efficiently and safely without using theactual robot.
As Figure 4 shows, it is possible to visually analyzeeach axis’ operation (position, speed, acceleration) while
confirming robot operations in 3D.
Even after the actual robot is installed, operations can be
confirmed using simulation. Moreover, video footage canFig. 2 External appearance of the teaching pendant

be recorded while logging motor speed, acceleration, andtorque data, and this information can be utilized to analyze
frequent robot stops or to improve cycle time.

Fig. 3 Robot hand setting screen
Table 1 Examples of main robot language
commands
Command name27

Description

Fig. 4 Screen of 3D simulation software

PTP

Point-to-point movement

LIN

Linear interpolation movement

CIRC

Circular interpolation movement

PTPRelDistance-specified PTP operation

LINRelDistance-specified linear interpolation operation

use the technologies in SANMOTION C to support the

StopRobot

Robot stop

development of robot operation programs in a short period

WaitFinished

Wait for robot command to processof time.

RefRobotAxis

Homing operation

TOOL

Tool coordinates setting

Ovl

Overlap setting (Path)

Ramp

Acceleration/deceleration curve setting

WaitTime

Wait time (timer)

systems are also required to have functions for monitoring

DIN.Wait

Wait for digital input

pa r t l i fe, equ ipment operat iona l st at u s , operat i ng

Dout. Set

Digital output setting (BOOL)

environment, and so forth.

WHILE ... DO

Iterative control

IF ... THEN

Branch instruction

SANYO DENKI Technical Report No.46 November 2018

In this way, even users without robot expertise can

3. Monitoring function
With the aim of improving productivity and quality, servo

This section explains the monitoring functions of the
SANMOTION R 3E Model servo amplifier.

Servo System Technologies Creating Monozukuri Changes

3.1 Service life prediction function

servo motor. By monitoring power consumption, it is

Ser vo equ ipment such as ser vo motors a nd ser vo

possible to ascertain the energy usage status of machinery

amplifiers are service life-limited components whichand production equipment. This helps to reduce thewear and deteriorate over time. In order to use products

factory’s overall energy costs and promote energy-saving.

for an extended period of time, regular part replacement

The SANMOTION R 3E Model servo amplifier is also

is necessary. However, part life differs depending on theequipped with a communication error monitoring function

operating conditions and operating environment, therefore

which monitors communication quality. By quantitatively

it is difficult to ascertain the appropriate replacementmonitoring communication quality, it is possible to prevent

timing. As such, SANYO DENKI has included a function

communication trouble caused by changes in equipment

to monitor the remaining life of the motor holding brakeover time and operating environment changes. Moreover,and relays, etc. used in inrush current prevention circuits.

when a problem does arise, it is possible to swiftly perform

The remaining life of these parts can be monitored throughtroubleshooting.

a motion network from the host controller. Moreover, as
shown in Figure 5, motor setup software can be used formonitoring.

4. Information and Communication
Technology
As mentioned above, a lot of i n for mation can beobtained from the servo system, such as remaining partlife and machine operating status. As shown in Figure 6,
this information can be collected and accumulated in hostproduction management systems, data servers, etc. via
devices on each level and a network.
In order to effectively utilize this information, there is aneed for ICT technology to easily transfer data from theservo equipment to the host device or data server. Thissection explains the ICT technologies SANYO DENKI is
working on for servo systems.
Production management system Management
・Manufacturing control,
and analysis
utilization of AI,
of information
・and schedulingFig. 5 Service life prediction screen in the motor
setup software

MES/AI(Management,
diagnosis, AI)

Ethernet OPC

Information network

Display and measurement system

Collection
and developmentof information

・Production management

and monitoring

K nowing a part’s remaining life makes it possible

SCADA / HMI(Measurement, recording)

Ethernet OPC

Host network

Control system

to schedule maintenance before breakdowns on servo

・Equipment and processequipment and machinery actually occur.

Controllers

For details on the service life prediction function, please

controlDiagnosis
and analysis
of operational status(Control, diagnosis, analysis)

RS485 RS232

Production equipment

refer to “New Product Introduction: SANMOTION R 3E

・Processing, assembling,

Model 400 VAC Input Servo Amplifier (150 A, 300 A)”(2) ofMotors and amplifiers

this Technical Report.

Informationflow

and conveying

Motion network

Sensing(Acquisition of device
information)

Fig. 6 Flow of production equipment information

3.2 Operational status monitoring function
The SA NMOTION R 3E Model servo amplifier is
equ ipped w it h nu merou s f u nct ion s to mon itor t heequipment operational status.
For example, it is possible to easily monitor motor andamplifier power consumption with a power consumption

4.1 Motion network communication
technology
In order to acquire a high volume of information from a
servo system, there is a need for a high-speed, large-capacity
motion network.

monitoring function that calculates the power consumption

The SANMOTION R 3E Model EtherCAT servo amplifier(3),based on the rotational speed and electric current of thewhich is compatible with high-speed motion networks, is

SANYO DENKI Technical Report No.46 November 201828

the optimal product for utilizing ICT technology on the
production line.

5.1 Example of use for robot development
support technologies

This servo amplifier achieves a minimal communication

Previously, the part insertion process for servo amplifier’s

cycle of 62.5 μs, meaning that the maximum data transfer

printed circuit board heavily depended on manual work andamount in one communication cycle is approximately 1.6

was known as a bottleneck process of the production line.

times greater than the conventional model. It is possible

To alleviate this bottleneck, we built a production system

to send information to the host controller in real-time,

utilizing robots. Figure 8 shows the external appearance of aincluding not only commands and feedback information

dual-arm robot developed in-house by SANYO DENKI.

required for servo motor control, but also monitoring

This in-house robot loads and unloads printed circuit

information such as remaining part life and equipment

boards to and from the in-circuit tester then transfers PCBs

operating environment.

to the downstream process.

By utilizing these features, naturally the performance ofmachinery is improved, but so too is the reliability of failure
detection, preventive maintenance, etc.
Preceding
processICT

4.2 Network connection technology
SANYO DENKI’s SANMOTION C motion controller
can easily establish communication between devices
through an OPC server and network library. Figure 7 shows
an example of network connection between devices.

MES (production management system)
Information
network

Host
network（OPC）（Ethernet（TCP/IP）
）

HMI

（OPC）

Stepping Servo
amplifierdriverMotionnetworkDual-arm robot
developed in-house

Fig. 8 External appearance of an in-housedeveloped dual-arm robot（Ethernet(TCP/IP))

SANMOTION C
controller

Next
process

PLC
equipment
I/O (sensor) equipment（Can,RS485）

Field
network

By using the robot development support technologies
of SANMOTION C, we were able to develop this robot
in one-third of the time typically required, and minimize
installation costs. The newly built part insertion processachieves four times greater productivity and two-thirds

Fig. 7 Network connection between devices

shorter lead time compared to the conventional process.
Moreover, it is possible to produce several different varietiesof PCBs on the same production line, therefore productivity

Users who develop communication programs only

and flexibility have been dramatically improved.

need to set parameters through GUI for the controller toautomatically establish communication between devices,thus enabling a network to be built in a short period of time.

5.2 Examples of use for monitoring
functions and ICT technology
Robots and automation equipment using SA N YO

5. Examples of use on SANYO DENKI’s
production line

DE N K I ’s SA N MO T ION pro duc t s h ave a l s o b e en

This section introduces examples of how we have applied

quality by utilizing the various types of information thattechnologies that support the development of robots, servo

can be obtained from the servo motors, encoders, and servo

system monitoring functions, and ICT technologies toamplifiers using such equipment.

SANYO DENKI’s monozukuri.

introduced to the servo motor production line. We havebegun initiatives to increase productivity and stabilize

As one example, this article will introduce how we haveused ICT technology on the rotor assembly line for compact
servo motors.

29

SANYO DENKI Technical Report No.46 November 2018

Servo System Technologies Creating Monozukuri Changes

This assembly line performs everything from attaching

improve productivity and flexibility. Moreover, SANYO

the magnet to the motor shaft to rotor inspection. As

DENKI wishes to incorporate the know-how relating to ICT

shown in Figure 9, the control system comprises of thetechnology verified on our production lines into developing

SANMOTION R 3E Model EtherCAT servo amplifier andtechnologies and products creating new values for our

the SANMOTION C controller.

customers, as well as creating change.

Data collection/
accumulation

Reference

Analysisby AI(1) Kodama, Tazaki and others: Development of the Motion Controller
SANMOTION CSANYO DENKI Technical Report No. 21 (2006-5)

Server(2) Chino, Koike and others: Development of the SANMOTION R 3E
Model 400 VAC Input Servo Amplifier (150 A, 300 A)
SANMOTION C
controller

Visualization
EtherCATSANYO DENKI Technical Report No.46 (2018-11)(3) Ito, Machida and others: Development of the SANMOTION R 3E
Model EtherCAT Servo Amplifier

SANMOTION R 3E Model
EtherCAT
servo amplifier

Monitoring

SANYO DENKI Technical Report No. 44 (2017-11)(Part life,
operation status,
etc.)

Hideaki Kodama
Rotor assembly line

Fig. 9 Example use of ICT technology on a rotor
assembly line

Joined SANYO DENKI in 1991.
Servo Systems Div., Design Dept. 2
Works on the design and developmentof controllers.

Yasutaka Narusawa
A large volume of information monitored by the servo
system, such as part life and power consumption, is sent to
the SANMOTION C controller in real-time by utilizing

Joined SANYO DENKI in 1991.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

the high-speed performance and efficient data transfer
of EtherCAT. Moreover, information acquired by the

Norio Nakamura

controller is accumulated in the data server.

Joined SANYO DENKI in 2007.
Servo Systems Div., Production Engineering Dept.
Works on the production technology of servo
motors.

By utilizing the data stored in the server, it is possible
to achieve visualization of remaining part life, equipment
operating status, amplifier operating status, and so on.
As such, users can expect many benefits from the support

Shusaku Magotake

functions that enable scheduled maintenance and enhanced

Joined SANYO DENKI in 1996.
Servo Systems Div., Production Engineering Dept.
Works on the production technology
of controllers and servo motors.

productivity of servo equipment. Moreover, by utilizing
machine learning such as AI, the large quantity of data thatis collected can be analyzed and used to verify symptom
detection for equipment failures and faults.

6. Conclusion
This article introduced robot development support
technologies, and the monitoring functions and IC T
technologies of servo systems as servo system technologies
creating monozukuri change. This article also provided
examples of SANYO DENKI’s monozukuri using thesetechnologies.
We will continue enhancing support technologies for the
introduction and utilization of robots in order to further

SANYO DENKI Technical Report No.46 November 201830

New Product Introduction

Development of the
SANMOTION R 3E Model 400 VAC
Input Servo Amplifier (150 A, 300 A)
Haruhiko Chino

Hiroaki Koike

Haruhiko Kamijyou

Yasuhiro Wakui

Masaki Miyashita

Satoshi Hiramitsu

1. Introduction

2.2 Main specifications
Table 1 shows the main specifications of the 150 A and

The SANMOTION R 3E Model 200 VAC input servo

300 A amplifiers. The interface supports analog and pulse

amplifier developed in 2014 features a wide range oftrain inputs, as well as EtherCAT. We have also added a

products able to drive motors with outputs of up to 30 kW,

functional safety model to the lineup, allowing customers toand is being used by customers in a variety of machinery.

choose the right one for their equipment’s application.

With the globalization of industry, a high demand for
400 VAC input servo amplifiers is emerging primarily in

Compatible motors are the R1 and R2 series 400 V input
motors with 5.5 to 30 kW outputs.

Europe and Asia, therefore SANYO DENKI has enhanced

Compatible encoders are our absolute encoders andthe lineup with new 400 VAC input models capable ofwire-saving incremental encoders. Moreover, these models

driving motors with the same outputs as the 200 VAC

also support encoders manufactured by HEIDENHAIN

models.

(EnDat2.2 interface) for use with linear motors or fully

This article will introduce the two new models added
to the SANMOTION R 3E Model 400 VAC input servo
amplifier lineup:150 A and 300 A.
First, an overview of the new models will be provided.
Next, the main performance, functions and development

closed-loop control systems.
The new models also comply with international standards
such as Eu rope’s L ow Voltage Di rective, the EMC
Directive, Functional Safety, UL/cUL (US), and KC mark(Korea).

points will be introduced.

2. Product Overview
2.1 Appearance and dimensions
Figure 1 shows the appearance of the SANMOTION R
3E Model 400 VAC input servo amplifiers with 150 A and
300 A capacities (hereinafter 150 A and 300 A models),
while Figures 2 and 3 show their dimensions.
In order to maintain compatibility with existing products,
the new models were given the same width and height
dimensions as the current models.

150 A
Analog/Pulse

300 A
EtherCAT (Safety)

Fig. 1 Appearance

31

SANYO DENKI Technical Report No.46 November 2018

Development of the SANMOTION R 3E Model 400 VAC Input Servo Amplifier (150 A, 300 A)

25

140

325

375

325
（25）

375

（80）

150

（70）

270

（85）

150

230

（25）

140

25

（70）

220

235

Fig. 2 Dimensions (150 A)

Fig. 3 Dimensions (300 A)

Table 1 Main specifications
Amplifier capacity

150 A

300 A
24 VDC ±10%

Control power supply voltage range

380 to 480 VAC +10%, -15%

Main circuit power supply voltage range

220 W × 375 H × 230 D

Dimensions

270 W × 375 H × 235 D

Continuous output current

34.0 Arms

66.0 Arms

Peak current

83.0 Arms

157.0 Arms

5.5 to 15 kW

20 to 30 kW

Compatible motor
Compatible encoder
Control function

・Absolute encoder (battery back-up, battery-less, single turn)・Wire-saving incremental encoder
・HEIDENHAIN EnDat2.2 encoder
・Tandem operation control
・Dual positioning feedback control

・FF vibration suppression control (2-Step)
Mechanical vibration/
・CP vibration suppression control
resonance suppression
・Adaptive notch filter

Function

Safetystandards

Servo tuning

・Auto tuning response 40 levels
・Servo tuning support function

Start-up, monitoring,
diagnosis

・Virtual motor operation
・Power consumption monitoring
・Drive recorder・Encoder temperature monitoring
・Amplifier temperature monitoring・Service life diagnosis of holding brake・Monitoring of power consumption of regenerative resistor
・Monitoring of encoder communication quality
・Relay clicking counterUL

UL 61800-5-1

CSA

C22.2 No.274-13

Low Voltage Directive

EN 61800-5-1

EMC Directive

EN 61800-3, EN 61326-3-1

Functional safety

ISO 13849-1 PL=e, EN 61508 SIL3, EN 62061 SILCL3

KC mark

KN 61000-6-2, KN 61000-6-4

SANYO DENKI Technical Report No.46 November 201832

3. Performance and Functions

3.4 Relay click counter
This function enables you to monitor the remaining

T he new mo del s of fer fou r new f u nc t ion s wh i lelife of components by counting the number of relay clicks

maintaining the same performance and functions as the

produced in the inrush current limiting circuit, dynamic

SANMOTION R 3E Model 200 VAC input servo amplifiers.

brake circuit, and holding brake output circuit. This

These functions acquire and analyze data relating to servo

enables systematic maintenance and prevents equipment

motors and servo amplifiers to improve the maintainability

breakdown.

of equ ipment th roug h preventive ma i ntena nc e a ndenvironmental diagnosis. The details of each function areprovided below.

3.1 Holding brake remaining life

4. Key Points of Development
4.1 Business continuity planning (BCP)
initiatives

A servo motor with a holding brake is a service life-

Our suppliers suffered extensive damage in the Great East

limited component as repetitive braking causes wear, which

Japan Earthquake in 2011 and Kumamoto Earthquake inin turn causes the gap to widen and, ultimately, prevents

2016, which made our part procurement difficult, affecting

normal operation.

our customers’ production. For example, we failed inThis function counts the number of the holding brake’s

procuring intelligent power modules (IPM) that we used as

braking rotation to estimate brake wear and monitor

the power module for servo amplifier inverters. We could

the remaining life of the holding brake. This enables

not find an alternative to it due to the lack of compatibility

customers to appropriately judge the timing of servo motorof the package and functions which differ by manufacturer,

replacement and prevent equipment breakdown.

and however, depending on the manufacturer, and a drastic
design change was required.

3.2 Monitoring of power consumptionof regenerative resistor
We have added a function to monitor power consumptionof regenerative resistor.

So, for the new 30 0 A servo amplifier, we selected
an IGBT module which is compatible with multiple
manu factu rer packages. A n I PM has many bu i lt-i nfunctions such as overload protection, over-heat protection,

I f the i nput voltage r ises a nd the capacity of theprotection against control circuit low voltage, and software

electrolytic capacitor decreases, the regenerative power

isolation in the case of overloads, while the IGBT module

increases. By monitoring power consumption, it is possible

does not offer these functions.

to detect changes in the power source environment andAs such, we newly designed a common circuit as adevice failures. Moreover, it also enables us to check the

periphery protection function of the IGBT module,

margin in relation to maximum absorbed power, therefore

achieving the same safety level as the IPM. By establishingcustomers can choose the suitable regenerative resistor.

these technologies, it became possible to purchase core
parts from multiple suppliers without changing the printed

3.3 Monitoring of encoder communication
quality

circuit board and continue production even in unforeseen
circumstances by minimizing damage.

A function has been added to the new models to monitor

This achieves one element of business continuity planning

communication error rate (bit error rate) and quantitatively(BCP) strategy, enabling us to stably deliver our products tocheck the quality of communication between the servo

customers.

amplifier and encoder.
The error rate varies significantly if there is a problem
with the servo amplifier-servo motor connection, grounding

33

4.2 Reduction of servo amplifier heatgeneration

connection, or a problem with the shielded cables. With thisIn order to reduce internal heat generation, we optimized

monitoring function, you can perform the correct wiring,

the electrolytic capacitor of the main circuit. By performing

grounding, etc. at the device start-up, improving the device’s

FFT analysis on the ripple current derived through circuit

noise resistance. Moreover, monitoring variations in thesimulation then calculating the heat generation amount fromerror rate during device operation helps in checking andthe electric current value of each frequency band, we selected

improving communication quality.

the optimal specifications for the electrolytic capacitor.

SANYO DENKI Technical Report No.46 November 2018

Development of the SANMOTION R 3E Model 400 VAC Input Servo Amplifier (150 A, 300 A)

Table 2 shows a comparison of the new and current
models’ main circuit electrolytic capacitors. By increasing

Inside control panel

the main circuit electrolytic capacitor’s allowable ripple

Inside duct

current by 35.8% compared to our conventional model(SANYO DENKI’s RS1 series), temperature rise has
decreased by 38.1%, thereby reducing heat generation.
Moreover, by providing feedback of evaluation results andconsidering the worst conditions for product specifications
and parts in the design phase, we have developed a productthat offers greater safety, greater security and higher quality.

Table 2 Comparison of main circuit electrolytic
capacitors
Item

Current model(RS1) 150 A

New models
150 A

Differencewith current
model

Temperaturerise

13.9 K

8.6 K-38.1%

Staticelectricity
capacity

2,000 µF2,180 µF

9.0%

9.0 Arms

12.3 Arms

35.8%

461,814 mm3-26.5%

7,697 mm

-2.0%

Allowable
rippleVolumeSurface area

628,319 mm3
7,854 mm3

3

Table 3 Comparison of depth and volume
with current model

4.3 Downsizing
As Figure 4 shows, the new models are installed within theback side. Table 3 gives a comparison of depth dimensions

150 A

with current models. For the current models, the front side
depth dimension (which previously differed depending on
amplifier capacity) has been standardized to 150 mm, andthe overall size has been reduced by up to 10%. Moreover,the safety function expansion board can be completely built
into the main unit, therefore it is possible to switch to the
SANMOTION R 3E Model Safety, which complies with

Depth
(Rear side)

Fig. 4 Amplifier depth

Capacity

control panel on the front side, and inside the duct on the

Depth(Front side)

300 A

Model
numberDepth(Front side)

Depth(Duct side)

VolumeReduction
rate

RS3C15(Newmodel)

150 mm

80 mm-2%

RS1C15(Currentmodel)

155 mm

80 mm

RS3C30(New
model)

150 mm

85 mm

RS1D30(Currentmodel)

160 mm

100 mm-10%functional safety standards, without changing amplifier
mounting positions within the control panel, or increasing
space occupancy.

SANYO DENKI Technical Report No.46 November 201834

Development of the SANMOTION R 3E Model 400 VAC Input Servo Amplifier (150 A, 300 A)

5. Conclusion
This article has introduced the main performance,
functions, and development points of the new models

Haruhiko Chino
Joined SANYO DENKI in 1983.
Servo Systems Div., Design Dept. 2
Works on the design and development of systemproducts.

added to the SANMOTION R 3E Model 400 VAC input
servo amplifier lineup: the 150 A amplifier and the 300 A

Hiroaki Koike

amplifier.

Joined SANYO DENKI in 1988.
Servo Systems Div., Design Dept. 2
Works on the design and development of systemproducts.

With the addition of these new models it is now possible
to combine supporting motors of up to 30 kW outputs,
which is equivalent to the SANMOTION R 3E Model
200 VAC input servo amplifiers. Furthermore, throughHaruhiko Kamijyou

newly added IoT functions, these models contribute to

Joined SANYO DENKI in 2005.
Servo Systems Div., Design Dept. 2
Works on the design and development of systemproducts.

improved equipment maintainability, failure prediction, andpreventive maintenance.
Moving forward, amidst market change and fluctuation,
SANYO DENKI will continue to constantly assess theYasuhiro Wakui

servo system requirements of our customers and develop

Joined SANYO DENKI in 2012.
Servo Systems Div., Design Dept. 2
Works on the design and development of systemproducts.

products which create new value. Moreover, so that ourcustomers may use our products safely and securely, we willfurther our efforts to improve design quality.

Masaki Miyashita
Joined SANYO DENKI in 2013.
Servo Systems Div., Design Dept. 2
Works on the design and development of systemproducts.

Satoshi Hiramitsu
Joined SANYO DENKI in 2017.
Servo Systems Div., Design Dept. 2
Works on the design and development of systemproducts.

35

SANYO DENKI Technical Report No.46 November 2018

46

November
2018

https://www.sanyodenki.com

Published in Japan on November 15, 2018 by SANYO DENKI CO.,LTD.
Published semi-yearly
3-33-1 Minami-Otsuka, Toshima-ku, Tokyo 170-8451, Japan
Phone +81 3 5927 1020
Publisher Shigeo Yamamoto
Editorial Board Members:
Nobumasa Kodama
Editor-in-Chief
Satoru Onodera
Managing Editor
Shiho Tsukada
Secretary
Masafumi Yokota
Kenta Nishimaki
Kiyoshi Mizuguchi
Masakazu Uchida
Daigo Kuraishi
Hideki Netsu
Hiroshi Miyazaki
Rieko Komine
Copyright © 2018 SANYO DENKI CO., LTD.
All rights reserved.
No part of this publication may be reproduced in any manner whatsoever without written
permission from SANYO DENKI.
All company and product names used in this publication are trademarks or registeredtrademarks of their respective companies.